Prefabricated building unit and wall



y 30, 1939- Mi (5. HILPERT EREFABRICATED BUILDING UNIT AND WALL FiledFeb. 5, 1957 4 Sheets-Sheet 1 y l L J I l I gwvq/wbob fleierGeo. Hi/Q aMay 30, |L RT 2,159,991

' PREFABRICATED BUILDING UNIT AND WALL Filed Feb. 3, 1957 4 Sheets-Sheet2 ig;g .az 34 ,5

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OHM/wag May 30, I G. RT I PREFABRICATED BUILDING UNIT AND WALL FiledFeb. 5, 1957 4 Sheets-Sheet 3 Meier Gemflilbezd? May 1939- A M. G.HILPERT 2,159,991

PREFABRICATED BUILDING UNIT AND WALL Filed Feb. 5, 19s? 4 Sheets-Sheet 4Me ifergeouHi/pert, v I

Patented May 30, 1939 UNITED STATES PATENT OFFICE J 8 Claims.

This invention relates to slabs, capable of varied uses but especiallyintended for use in forming the walls, floors and roofs and the floorsplus ceilings and the roofs plus ceilings, of pre-fabricated buildingconstructions preferably having steel frames and if desired, stucco, orGunite,

or brick veneer exterior finishes, and has gen-' the accompanyingdrawings and defineddn the appended claims.

In the drawings:

Figure l is a plan view of a grid-like rein-. forcement for the top orouter wall of a slab.

Figure 2 is a plan view of a grid-like rein-- forcement for the bottomor inner portions of the 25 side and end walls and the ribs of a slab,including chairs for the attachment of additional reinforcements.

Figure 3 is a longitudinal sectional view showing the relativearrangement of the reinforcing so elements of Figures 1 and 2 and cellforming core elements within a form preparatory to pouring the bodyportion of one of the present slabs. Figures-4 and 5 are fragmentarysectional and plan views, respectively, of a combined clip and as chairused in the constructionof the present slab. Figure 6 isa plan view of acompleted body portion of a floor or roof slab.

Figure 7 'is a longitudinal-section through a completed body portion ofa floor .or roofslab it) with the cell forms and exterior forms removedand provided with thermal insulation.

. Figure 8 is a longitudinal section through a v 'flnished floor or roofslab showing the plastic cast ceilingforming closures for the cellsthereof. Figure 9 is a fragmentary-sectional view showing a jointbetween two adjacent floor or roof slabs.

Figure 10 is a view similar to Figure 9 illusm trating an alternativeslab and jointcon'struction. I

, Figure 11 is a plan'view of a wall slab equipped with a hole for thereception of a lifting device and with anchors for retaining a stucco,Gunite or brick weneer exterior finish.

(c1. 'zzi) Figure 12 is a transverse section on the line. |2- -l2 ofFigure 11.

Figure 13 is a view similar to Figure 12 showing a modification inapplying thermal insulation.

Figure 14 slab.

Figure 15 is an elevation of a wall having slab load and lockingelements extending between the slabs forming said wall. 10

t Figure 16 is a horizontal section through the wall joint showing theloading and locking elements in elevation.

Figure 17 is a sectional, perspective view of a portion-of a buildingconstructed with slabs and elements in their proper relation to a steelframe all in accordance with the invention.

Referringto the drawings in detail, first with particular reference tothe floor or roof, or floor plus ceiling, or roof plus ceiling, slabillustrated in Figures 6 to 10, A designates, generally, the slab bodywhich in accordance with the invenis a sectional view through a walltion, is of rectangular shape and may be formed from any suitablematerial such as ordinary concrete or the like, or cinder concrete,Haydite" or the like having thermal insulating value in itself.

The body A may be of any desired length, breadth and thickness and is ofclosed-top, cellular construction having the cells thereof openingthrough its bottom. That is to say, the body A comprises a top wall in,side walls II and end walls l2, and has depending from its top wall tothe plane of its bottom, one or more strengthening ribs- I3 extendinglongitudinally from end to end thereof, and one or more strengtheningIlDS l4 extending transversely from side to side thereof, the said ribscooperating with each other and with the side and end walls to definethe cells,' designated as l5, which open through the bottom of the bodyA as stated.

In the top wall I0 is embedded suitable reinforcing means whichconveniently may comprise a plurality of rods I 6 and I1 extendinglongitudinally and transversely of said wall, said rods l6 and Ilpreferably. but not necessarily, being suitably joined together at thepoints where they extend across or intersect each other. In addition,other reinforcing rods i 8 and I9 are embedded in the bottoms of theribs [3 and. i4, respectively, and extend longitudinally thereof, saidrods l8 and I9, as in the case of rods l6 and Il, also preferably, butnot necessarily, being suitably joined together at the points where theyextend across or intersect eaehother.

clips 20 from side to side of the slab body A are -rods 22 which serveas reinforcements for a relatively thin slab bottom closure 23 of cementor the likehaving at the bottom thereof additional transverselyextending reinforcingrods 22'.

In some casesit may not be necessary or desirable to have finishedceilings at the under sides of the floor or root slabs A. On that event,in forming the slabs, the rods l8 need not be equipped with the clips 20for holding the rods 22 and said rods 22 and the bottom closure 23 neednot be provided. In other words, the cells l5 may remain open at theirbottoms. On the other hand, in cases where it is necessary or desirableto have finished ceilings at the under sides of the slabs A, the bottomclosures 23 therefore and the reinforcing rods 22 held by the clips 20or their equivalent are provided, the said bottom closures forming thefinished ceilings as is apparent. 1

Preferably the cells l5 are lined with metallated paper or othersuitable material 26 whereby the heat losses of the slab are greatlyreduced and moisture and air are prevented from finding their waythrough the slab. Alternatively, the cells l5 may be filled, or partlyfilled, with other suitable heat and sound insulating material such, forexample, as bulk insulation, designated as 25, which may be retained insaid cells in any suitable manner, as, for example, by being stuck tothe interior cell walls before applying the closure 23, or by means ofbowed rods or wires 26 engaged at their ends against the cell side and,or,

,end walls, as illustrated in connection with the wall slab shown inFigure 12, or alternatively, the bulk insulation may be carried on asheet of paper resting on the rods 22 and provided with upturned edges,or it may be placed on top of and around the sides of the core elementsemployed in forming the slab, prior to the pouring of the material tocomprise the slab over said core elements.

, The slabs A are adapted to be suitably supported in side to side andend to end relationship with their ends resting upon the flanges ofbeams or girders, and are adapted to have the spaces between them filledby concrete or other suitable material which may present either the samesurface color as the slabs or any contrasting color to form anatttractive fioor design. In any event, to adapt the slabs, whendisposed in side to side and end to end relationship, to havespacesformed therebetween for the reception of slab binding fillers ofconcrete or the like, the outer faces of the side and end walls of theslabs, according to one practical form of the invention, are downwardlyand outwardly inclined as indicated at 21. This results in the forming,between any two adjacent slabs, of a V-shaped channel for the placing ofI-beam tie rods and for the reception of a binding material designatedas 28, which may, if desired, be covered by a reinforced layer 29 of thesame material as the slab body. Moreover, this beveling or inclining ofthe side and the end walls of the slab body provides for the forming ofa binding material re-.

or the like on the flange of which the side or end of the slab 'rests,the I-beam or the like being thus fireproofed by said binding material.

Obviously, instead of beveling the sides and ends of the slab body toprovide for the forming of binding material receiving channels betweenthe slabs, the same result may be obtained by forming the bottom portionof the slab body at its sides and ends with an outwardly directed flange30, in which event the outer faces of the slab body above said flangemay be either perpendicular to the plane of the slab body, or inclined,as may be desired. In either case, when the flanges of any two slabs arebrought into edge to edge abutting relationship, as illustrated inFigure 10, a binding material receiving channel is formed between theslabs as is apparent. Also, it is apparent that in the case of anyterminal slab resting upon the flanges of I-beams, or the like, there isformed a binding material receiving channel between the adjacent wall orgirder and the side of the slab body.

In Figures ll to 16 of the drawings are illustrated wall slabs,designated as B, which are of generally the same construction as thefioor or roof, or floor plus ceiling, or roof-plus ceiling slabsillustrated in Figures 6 to 10. That is to say, the bodies of said wallslabs are of rectangular shape and may be formed from any of theextending ribs, l3 and M respectively, integral with and extendinginwardly from their closed outer sides l0. At their inner sides they maybe either left open or unfinished or they may be closed by thin walls23' as in the case of the slabs A. Moreover, the cells I5 may be linedwith metallated paper or may be filed, or partly filled, with bulkinsulation which may be retained in said cells in any suitable ordesired manner. Instead of the edges of the slabs B being beveled orstepped as in the case of the slabs A, the edges of said slabs Bpreferably are fiat and are disposed perpendicularly to the planes ofthe slabs.

As it is intended that the wall slabs B are to be made of considerablesize they may be quite heavy and, in the absence of special means tofacilitate their handling, they may be difiicult to handle. Accordingly,and as illustrated in Figures 11 and 12 of the drawings, therepreferably is formed through each slab B, transversely thereof, a hole3| through which a rod, pipe or the like may be passsed for use inlifting or otherwise handling the slab. This hole may be formed at anydesired point. Preferably, however, it is formed approximately midwaybetween the ends of the slab, through one of the ribs l3' or M or atapoint where a pair of these ribs intersect. Moreover, the concrete orother material comprising the slab body preferably is reinforcedadjacent to said hole as illustrated, for example, in Figure l2, bymeans of a rod or wire 32 bent upon itself and embedded in one of theribs l3 7 cells and is suitably secured therein as by placing flatbottom or is disposed upon a suitable flat surface s. In addition, thereis provided, as illustrated in Figure l, a section of the crossed rodsor wires I6, I 1 substantially corresponding in length and width to thetop wall III of the slab body to be formed, and, as illustrated inFigure 2, a section of the crossed'rods or wires l8, I9 spacedcorrespondingly to the spacing of the ribs l3 and I 4 to be formed, thewires or rods of said sections being wire tied together so that they mayreadily be adjusted'relatively to each other for use in forming slabs ofdifferent sizes. Moreover, there are provided a number of closed-top,closed-side, pan-like elements 35 to serve as cores for forming thecells l5. At points suitably spaced along the wires l8 or l9, dependingupon whether it is desired that the bottom closure reinforcing rods 22shall extend transversely, or longitudinally of the completed slab, areplaced the clips 20 in alined rows transversely or longitudinally of therods 18 and I9 slightly above said surface.-

Within the rectangular space between each two adjacent rods 18, I8 and I9, I9 is placed one of the pan-like core elements 35, the same restingon the surface s and having downwardly and outwardly sloping side andend walls of which the side walls engage the ends of the clips 20,whereby said core elements-are held properly positioned relative to therods l8. As is understood, the pan-like elements 35 are arranged in rowslongitudinally and transversely with the elements spaced apartcorresponding to the width of the ribs l3 and I4 to'be formed. Foreither of the slabs A or B there may be disposed in coveringrelationship to each core-element a sheet of the metallized paper or thelike 24. Supported in any suitable manner at suitable distances abovethe tops of the core elements 35 is the grid-like section of crossedrods or wires l3, II. In addition, if the slabis to be provided with thehole 3| a suitable core, such as an ordinary paper mailing tube, isplaced in upright position at the point where the hole is to be locatedand the reinforcing wire or rod 32 is supported in proper position bymeans of said core. The concrete or other material from which the slabis to be formed then is mixed, or, already mixed and in plasticcondition, is poured into the form F until it fllls the spaces betweenthe core elements 35, therebyforming the ribs I 3' and I4, or I 3' andI4, as the case may be, and until it rises suitably above the tops ofthe core elements toform the top wall I0 or lfl' of the slab body, A orB as the case may be. Thereby, the reinforcing rods or wires l6, l1beco'me embedded in the top wall l0, and the rods or wires I8, 19 becomecentrally embedded in the bottoms of, the ribs l3, l4 with the eyes 2|of the clips- 20 presenting openings at the bottom of and through saidribs to receive the wires or rods 22. Thereafter, the wires 34, if sameare used, are forced in the plastic top of the slab body.

After hardening of the concrete or other material from which the slabbody is formed, the form F is removed, the slab body is lifted from thesurface s, and the core elements are re- ,moved, leaving within thecells li for wall slabs the metallized paperor equivalent linings 24. Ifanlalternatethermal insulation is to be used and the cells are to befilled or partiallyfllled with insulating material asfqrroof or overbasement slabs, this material then is placed within said stucco andplaster.

on paper and resting on rods 22 or by means of the rods or wires 26. Thebottom closure reinforcing rods 22 then are inserted through'the eyes 2|of the clips 20 and the bottom closure 23 is applied in any suitablemanner, becoming united with the slab body through the instrumentalityof the rods 22 and the clips 2| and serving effectively to close thebottom of the slab. In

this connection one suitable manner of applying I the bottom closure 23is to providea form corresponding in length and width to the bottom ofthe slab body; to pour into this form a quantity of the material inplastic form from which the bottom closure is to be formed until thematerial assumes the form of a sheet of the desired depth or thickness;then to lower the slab body into said form until the bottom of the slabbody embeds in the plastic material, and finally to permit the plasticmaterial to harden. This obviously results in the rods or wires 22becoming embedded in and reinforcing the bottom closure and, at the sametime results in the bottom closure becoming securely bonded to the slabbody in effective closing relationship to the bottom thereof. As aresult the finished slab is of hollow, cellular form, light in weight,strong, weatherit is important that all of the prefabricated wall unitsbe capable of expeditious assembly to promptly provide all exterior andinterior surfaces for finishing, as afollowingoperation, and that alljoints shall be well bonded as against contractive and expansive forcesand other forces such as the weight of'the units or wind pressureagainst the wall slabs, or even earthquake forces. fore, the wall slabsare provided with flat sides Thereperpendicular to their planes and wiremesh or rods or the like 33 having T-shaped or equivalent ends, is orare employed between adjacent slabs as illustrated in Figures 15, 16 and17. The rods 36 extend transversely between the slabs at suit-- ablyspaced apart intervals and their T-shaped or equivalent ends overlie theinner and the outer faces of the slabs. Thereby, the slabs are supportedin slightly spaced ,apart relationship and are interlocked againstlateral movement relative to each other, especially, when the T-shapedor equivalent ends of the rods are embedded in 9 Moreover, when stuccoor the like is applied to the outer sides of the wall slabs and plasteris applied to the innersides of said slabs, it is pushed into the spacesbetween the slabs and providesadditional bearing, area betweenlthe slabsand insulating air spaces within the joints. The rods 38, moreover,assure uniform,- thin joints between the slabs andpermit slabsstaple-like anchors preferably of several pieces of galvanized wiretwisted together for greater bonding value for both the exposed portionand the embedded portions. As the "exterior finish is applied, that is,as the brick veneer wall is laid up, the usual brick wall galvanizedwall anchors are made to engage the slab staples and are moztared intothe brick wall joints and thus the exterior finish is thoroughly tied tothe locked wall slabs and shored against same by the excess veneermortar bridging, at places, the usual insulating air space between thewall slabs and the veneer wall. The wall slab staples also act asaccurate spacers for the width of the air space between the slab walland the veneer wall, since the staples are placed in the prefabricatedwall slabs by shop methods so as to extend exact distances beyond theexterior surfaces of slabs.

For veneer walls it will be provided that the veneer wall be foundedslightly below the bottom slab joint and said slab joints thoroughlymortared exteriorly so that moisture invading the air space between theveneer wall and the slab wall will escape through the lower and exteriorveneer wall joint, thus avoiding a serious defect of the ordinary veneerwall of brick, stone or tile.

' Without further description it is thought that the features andadvantages of the invention will be readily apparent to those skilled inthe art,

and it will of course, be understood, that changes in the form,proportion. and minor details of construction may be resorted to,without departing from the spirit of the invention or scope of theappended claims.

I claim: r

1. A building slab comprising a body portion having a top or outer wall,side and end walls, and ribs extending inwardly from the top or outerwall and cooperating with the side and end walls to form cells withinsaid body portion, metallized paper linings for said cells, and a bottomor inner side closure for said slab body.

2. A building slab' comprising a body portion of closed top hollow form,clips embeddedinsaid cooperating with said faces to hold the slabsagainst inward or outward movement relative to each other.

4. A building slab having a top or outer wall, side and end walls, andribs extending from the top or outer wall and cooperating with said sideand end walls to form cells within the slab, re-

lnforcement means within the ribs near the bottom or inner ends thereof,and eyed clips, cariied by said reinforcement means and extending beyondthe bottom or inner faces of said ribs for holding reinforcement meansfor a bottom or inner side closure for said slab.

5. A wall comprising superimposed pre-formed slabs, slab spacingelements extending transversely of said wall between adjacent slabsholding the latter spaced apart, and formations at the ends of saidspacing elements overlying the inner and the outer faces of the slabsand providlng retaining and reinforcing means for plaster at the innerside of the wall and a finishing veneer or stucco at the outer side ofthe wall.

6.'A wall as set forth in claim 5 having a finishing veneer or stucco atits outer side and plaster at its inner side, the veneer or stucco andthe plaster extending into the spaces between the slabs.

7. A building slab having a hole formed transversely therethrough andopening at opposite sides thereof for the reception of a liftingelement, and slab reinforcing means embedded in said slab in surroundingrelationship to said hole.

8. A building slab comprising a body portion having a top or outer wall,side and end walls, and ribs extending inwardly from the top or outerwall and cooperating with the side and end wall, to form cells withinsaid body portion, heat and sound insulating material within. saidcells, yielding means sprung into the cells from the open side thereofto hold the insulation material against said top or outer wall and theside walls of said cells, said yielding means engaging the oppositewalls of the cells thereby to be held in place, and a bottom or innerside closure for said body portion and closing said cells.

MEIER GEO. HILPERT.

